Solid golf ball

ABSTRACT

The invention provides a solid golf ball having a solid core, a cover layer that encloses the core, and a plurality of dimples formed on an outside surface of an outermost layer of the cover. The solid core is formed of a rubber composition composed of 100 parts by weight of a base rubber that includes 60 to 100 parts by weight of a polybutadiene rubber having a cis-1,4 bond content of at least 60% and synthesized using a rare-earth catalyst, 0.1 to 5 parts by weight of an organosulfur compound, and an unsaturated carboxylic acid or a metal salt thereof, an organic peroxide and an inorganic filler. The solid core has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kg, of 2.0 to 3.5 mm, and has a specific hardness distribution. The cover layer, which is formed by injection-molding a single resin composition of primarily (A) a thermoplastic polyurethane and (B) a polyisocyanate compound, and at least some polyisocyanate compound in which all the isocyanate groups on the molecule remain in an unreacted state is present in the resin composition, and has a thickness of 0.5 to 2.5 mm, a Shore D hardness at the surface of 50 to 70. The core has a surface hardness which is from 1 to 15 Shore D hardness units lower than the surface hardness of the core. The golf ball has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kgf, of 2.0 to 2.9 mm. The solid golf ball is advantageous overall in competitive use.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of copending application Ser. No. 11/293,226 filed on Dec. 5, 2005, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a solid golf ball having a solid core and a cover layer which encloses the core. More particularly, the invention relates to a solid golf ball which is conferred with a high rebound on full shots with a driver so as to increase carry, which also has a good performance on approach shots and a good feel on impact, and which moreover has an excellent scuff resistance.

Golf balls designed to satisfy the overall characteristics desired in a golf ball, such as good flight properties, feel on impact and controllability on approach shots, have hitherto been improved in various ways. One example is the golf ball described in JP-A 6-98949.

However, because this golf ball has a hard cover, there are problems with its spin performance.

In addition, JP-A 9-308708, JP-A 2003-70936 and JP-A 2003-180879, for example, disclose solid golf balls in which the feel and controllability have been improved without a loss of rebound or cut resistance by setting the thickness, flexural rigidity and Shore D hardness of the cover within specific ranges.

Yet, because this golf ball has an inadequate core resilience and the core hardness distribution has not been optimized, properties such as the carry and the spin performance leave something to be desired.

JP-A 9-215778 and JP-A 9-271538 disclose solid golf balls in which a polyurethane material is used as the cover material. However, in these golf balls, the core lacks an adequate resilience and the resin from which the cover is formed has an inadequate scuff resistance. Hence, there remains room for improvement in the carry of the ball and the scuff resistance of the cover.

The golf balls described in JP-A 2002-355338 and JP-A 2004-180793 do have a good core resilience, but because these balls have a large deflection hardness and are soft, the rebound by the ball decreases, resulting in a less that satisfactory carry.

It is thus an object of the present invention to provide a solid golf ball which is conferred with a high rebound on full shots with a driver so as to increase carry, which has a good spin performance on approach shots and a good feel on impact, and which moreover has an excellent scuff resistance.

SUMMARY OF THE INVENTION

We have conducted extensive investigations in order to achieve the above object. As a result, we have found that by optimizing primarily the hardness distribution in the solid core and optimizing the relationship between the cover surface and core surface hardnesses, there can be obtained a solid golf ball having an excellent spin performance on approach shots, an improved carry on full shots due to a lower spin, and a good feel on impact. Moreover, compared with conventional cover layers made of materials such as ionomer resins, this solid golf ball has a low flexural rigidity for the hardness of the cover layer, which affords the ball an excellent spin performance and stability thereof. In addition, this solid golf ball has an excellent scuff resistance and excellent durability to cracking with repeated impact. Based on these findings, the solid golf ball of the invention has the following solid core I and cover layer II.

I. Solid Core

(i) The solid core is formed of a rubber composition composed of 100 parts by weight of a base rubber that includes 60 to 100 parts by weight of a polybutadiene rubber having a cis-1,4 bond content of at least 60% and synthesized using a rare-earth catalyst, 0.1 to 5 parts by weight of an organosulfur compound, and an unsaturated carboxylic acid or a metal salt thereof, an organic peroxide, and an inorganic filler.

(ii) The solid core has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kg, of 2.0 to 3.5 mm.

(iii) The solid core has the hardness distribution shown in the table below. TABLE 1 Hardness Distribution in Solid Core Shore D hardness Center 35 to 55 Region located 5 to 10 mm from center 39 to 58 Region located 15 mm from center 48 to 66 Surface 50 to 68 Hardness difference between center and surface  5 to 20 II. Cover Layer (i) The cover layer is formed by injection-molding a single resin composition of primarily (A) a thermoplastic polyurethane and (B) a polyisocyanate compound, and at least some polyisocyanate compound in which all the isocyanate groups on the molecule remain in an unreacted state is present in the resin composition. (ii) The cover layer has a thickness of 0.5 to 2.5 mm, a Shore D hardness at the surface of 50 to 70 and the surface hardness of the core is from 1 to 15 Shore D hardness units lower than the surface hardness of the cover.

Accordingly, the invention provides the following solid golf balls.

[1] A solid golf ball having a solid core, a cover layer that encloses the core, and a plurality of dimples formed on an outside surface of an outermost layer of the cover, the solid golf ball being characterized in that the solid core is formed of a rubber composition composed of 100 parts by weight of a base rubber that includes 60 to 100 parts by weight of a polybutadiene rubber having a cis-1,4 bond content of at least 60% and synthesized using a rare-earth catalyst, 0.1 to 5 parts by weight of an organosulfur compound, and an unsaturated carboxylic acid or a metal salt thereof, an organic peroxide and an inorganic filler; the solid core has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kg, of 2.0 to 3.5 mm, and has the hardness distribution shown in Table 1 above; the cover layer is formed by injection-molding a single resin composition of primarily (A) a thermoplastic polyurethane and (B) a polyisocyanate compound, and at least some polyisocyanate compound in which all the isocyanate groups on the molecule remain in an unreacted state is present in the resin composition, and has a thickness of 0.5 to 2.5 mm, a Shore D hardness at the surface of 50 to 70 and the surface hardness of the core is from 1 to 15 Shore D hardness units lower than the surface hardness of the cover; and the golf ball has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kgf, of 2.0 to 2.9 mm.

[2] The solid golf ball of [1] above, wherein the solid core has a diameter of 37.6 to 43.0 mm and the golf ball has a diameter of 42.67 to 44.0 mm.

[3] The solid golf ball of [1] above, wherein the solid core contains, per 100 parts by weight of the base rubber: 30 to 45 parts by weight of the unsaturated carboxylic acid or a metal salt thereof, 0.1 to 0.5 part by weight of the organic peroxide, 5 to 80 parts by weight of the inorganic filler, and 0 to 0.2 part by weight of an antioxidant.

[4] The solid golf ball of [1] above which has a hardness difference between any two places in the region of the solid core located 5 to 10 mm from the center of not more than ±2 Shore D hardness units.

[5] The solid golf ball of [1] above, wherein the dimples total in number from 250 to 450, have an average depth of 0.125 to 0.170 mm and an average diameter of 3.5 to 5.0 mm for all dimples, and are configured from at least four dimple types.

[6] The solid golf ball of [1], wherein the resin composition additionally includes (C) a thermoplastic elastomer other than thermoplastic polyurethane.

[7] The solid golf ball of [6], wherein some of the isocyanate groups in component B form bonds with active hydrogens in component A and/or component C, and the other isocyanate groups remain in an unreacted state within the resin composition.

[8] The solid golf ball of [6], wherein the weight ratio (A):(B):(C) of the respective components is 100:{2-50}:{0-50}.

[9] The solid golf ball of [6], wherein the weight ratio (A):(B):(C) of the respective components is 100:{2-30}:{8-50}.

[10 ] The solid golf ball of [1], wherein the total weight of components A and B combined is at most 90 wt % of the overall weight of the cover layer.

[11] The solid golf ball of [1], wherein the resin composition has a melt mass flow rate (MFR) at 210° C. of at least 5 g/10 min.

[12] The solid golf ball of [1], wherein component B is one or more polyisocyanate compound selected from the group consisting of 4,4′-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, p-phenylene diisocyanate, xylylene diisocyanate, naphthylene-1,5-diisocyanate, tetramethylxylene diisocyanate, hydrogenated xylylene diisocyanate, dicyclohexylmethane diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, norbornene diisocyanate, trimethylhexamethylene diisocyanate and dimer acid diisocyanate.

[13] The solid golf ball of [1], wherein component B is one or more polyisocyanate compound selected from the group consisting of 4,4′-diphenylmethane diisocyanate, dicyclohexylmethane diisocyanate and isophorone diisocyanate.

[14] The solid golf ball of [1], wherein component C is one or more thermoplastic elastomer selected from the group consisting of polyester elastomers, polyamide elastomers, ionomer resins, styrene block elastomers, hydrogenated styrene-butadiene rubbers, styrene-ethylene/butylene-ethylene block copolymers and modified forms thereof, ethylene-ethylene/butylene-ethylene block copolymers and modified forms thereof, styrene-ethylene/butylene-styrene block copolymers and modified forms thereof, ABS resins, polyacetals, polyethylenes and nylon resins.

[15] The solid golf ball of [1], wherein component C is one or more selected from the group consisting of polyester elastomers, polyamide elastomers and polyacetals.

DETAILED DESCRIPTION OF THE INVENTION

The invention is described more fully below. The solid golf ball according to the invention has a solid core and a cover of one or more layers which encloses the solid core.

The solid core is a hot-molded material made of a rubber composition in which polybutadiene serves as the base rubber.

The polybutadiene must have a cis-1,4 bond content of at least 60%, preferably at least 80%, more preferably at least 90%, and most preferably at least 95%; and a 1,2-vinyl bond content of generally 2% or less, preferably 1.7% or less, even more preferably 1.5% or less, and most preferably 1.3% or less. Outside of this range, the rebound decreases.

It is recommended that the polybutadiene have a Mooney viscosity (ML₁₊₄ (100° C.)) of at least 30, preferably at least 35, more preferably at least 40, even more preferably at least 50, and most preferably at least 52, but preferably not more than 100, more preferably not more than 80, even more preferably not more than 70, and most preferably not more than 60.

The term “Mooney viscosity” used herein refers in each instance to an industrial indicator of viscosity (JIS K6300) as measured with a Mooney viscometer, which is a type of rotary plastometer. The unit symbol used is ML₁₊₄ (100° C.), where “M” stands for Mooney viscosity, “L” stands for large rotor (L-type), “1+4” stands for a pre-heating time of 1 minute and a rotor rotation time of 4 minutes, and the “100° C.” indicates that measurement was carried out at a temperature of 100° C.

The polybutadiene has a polydispersity index Mw/Mn (where Mw is the weight-average molecular weight, and Mn is the number-average molecular weight) of generally at least 2.0, preferably at least 2.2, more preferably at least 2.4, and even more preferably at least 2.6, but generally not more than 6.0, preferably not more than 5.0, more preferably not more than 4.0, and even more preferably not more than 3.4. A polydispersity Mw/Mn which is too small may lower the workability, whereas one that is too large may lower the rebound.

The polybutadiene is one that is synthesized with a rare-earth catalyst. A known rare-earth catalyst may be used for this purpose.

Exemplary rare-earth catalysts include those made up of a combination of a lanthanide series rare-earth compound, an organoaluminum compound, an alumoxane, a halogen-bearing compound and an optional Lewis base.

Examples of suitable lanthanide series rare-earth compounds include halides, carboxylates, alcoholates, thioalcoholates and amides of atomic number 57 to 71 metals.

Organoaluminum compounds that may be used include those of the formula AlR¹R²R³ (wherein R¹, R² and R³ are each independently a hydrogen or a hydrocarbon group of 1 to 8 carbons).

Preferred alumoxanes include compounds of the structures shown in formulas (I) and (II) below. The alumoxane association complexes described in Fine Chemical 23, No. 9, 5 (1994), J. Am. Chem. Soc. 115, 4971 (1993), and J. Am. Chem. Soc. 117, 6465 (1995) are also acceptable.

In the above formulas, R⁴ is a hydrocarbon group having 1 to 20 carbon atoms, and n is 2 or a larger integer.

Examples of halogen-bearing compounds that may be used include aluminum halides of the formula AlX_(n)R_(3-n) (wherein X is a halogen; R is a hydrocarbon group of 1 to 20 carbons, such as an alkyl, aryl or aralkyl; and n is 1, 1.5, 2 or 3); strontium halides such as Me₃SrCl, Me₂SrCl₂, MeSrHCl₂ and MeSrCl₃; and other metal halides such as silicon tetrachloride, tin tetrachloride and titanium tetrachloride.

The Lewis base can be used to form a complex with the lanthanide series rare-earth compound. Illustrative examples include acetylacetone and ketone alcohols.

In the practice of the invention, the use of a neodymium catalyst in which a neodymium compound serves as the lanthanide series rare-earth compound is particularly advantageous because it enables a polybutadiene rubber having a high cis-1,4 bond content and a low 1,2-vinyl bond content to be obtained at an excellent polymerization activity. Preferred examples of such rare-earth catalysts include those mentioned in JP-A 11-35633.

The polymerization of butadiene in the presence of a rare-earth catalyst may be carried out by bulk polymerization or vapor phase polymerization, either with or without the use of solvent, and at a polymerization temperature in a range of generally −30 to +150° C., and preferably 10 to 100° C.

The polybutadiene may be a modified polybutadiene obtained by polymerization using the above-described rare-earth catalyst, followed by the reaction of a terminal modifier with active end groups on the polymer.

A known terminal modifier may be used for this purpose. Illustrative examples include compounds of types (1) to (7) below.

-   -   (1) The modified polybutadiene can be obtained by reacting an         alkoxysilyl group-bearing compound with active end groups on the         polymer. Preferred alkoxysilyl group-bearing compounds are         alkoxysilane compounds having at least one epoxy group or         isocyanate group on the molecule. Specific examples include         epoxy group-bearing alkoxysilanes such as         3-glycidyloxypropyltrimethoxysilane,         3-glycidyloxypropyltriethoxysilane,         (3-glycidyloxypropyl)methyldimethoxysilane,         (3-glycidyloxypropyl)methyldiethoxysilane,         β-(3,4-epoxycyclohexyl)trimethoxysilane,         β-(3,4-epoxycyclohexyl)triethoxysilane,         β-(3,4-epoxycyclohexyl)methyldimethoxysilane,         β-(3,4-epoxycyclohexyl)ethyldimethoxysilane, condensation         products of 3-glycidyloxypropyltrimethoxysilane, and         condensation products of         (3-glycidyloxypropyl)methyl-dimethoxysilane; and isocyanate         group-bearing alkoxysilane compounds such as         3-isocyanatopropyltrimethoxysilane,         3-isocyanatopropyltriethoxysilane,         (3-isocyanatopropyl)methyldimethoxysilane,         (3-isocyanatopropyl)methyldiethoxysilane, condensation products         of 3-isocyanatopropyltrimethoxysilane and condensation products         of (3-isocyanatopropyl)methyl-dimethoxysilane.     -   A Lewis acid can be added to accelerate the reaction when the         above alkoxysilyl group-bearing compound is reacted with active         end groups. The Lewis acid acts as a catalyst to promote the         coupling reaction, thus improving cold flow by the modified         polymer and providing a better shelf stability. Examples of         suitable Lewis acids include dialkyltin dialkyl malates,         dialkyltin dicarboxylates and aluminum trialkoxides.

Other types of terminal modifiers that may be used include:

-   -   (2) halogenated organometallic compounds, halogenated metallic         compounds and organometallic compounds of the general formulas         R⁵ _(n)M′X_(4-n), M′X₄, M′X₃, R⁵ _(n)M′(—R⁶—COOR⁷)_(4-n) or R⁵         _(n)M′ (—R⁶—COR⁷)_(4-n) (wherein R⁵ and R⁶ are each         independently a hydrocarbon group of 1 to 20 carbons; R⁷ is a         hydrocarbon group of 1 to 20 carbons which may contain pendant         carbonyl or ester groups; M′ is a tin, silicon, germanium or         phosphorus atom; X is a halogen atom; and n is an integer from 0         to 3);     -   (3) heterocumulene compounds having on the molecule a Y═C=Z         linkage (wherein Y is a carbon, oxygen, nitrogen or sulfur atom;         and Z is an oxygen, nitrogen or sulfur atom);     -   (4) three-membered heterocyclic compounds containing on the         molecule the following bonds     -   (wherein Y is an oxygen, nitrogen or sulfur atom);     -   (5) halogenated isocyano compounds;     -   (6) carboxylic acids, acid halides, ester compounds, carbonate         compounds and acid anhydrides of the formula R⁸—(COOH)_(m),         R⁹(COX)_(m), R¹⁰—(COO—R¹¹), R¹²—OCOO—R¹³, R¹⁴—(COOCO—R¹⁵)_(m) or     -   (wherein R⁸ to R¹⁶ are each independently a hydrocarbon group of         1 to 50 carbons, X is a halogen atom, and m is an integer from 1         to 5); and     -   (7) carboxylic acid metal salts of the formula R¹⁷ _(l)M″         (OCOR¹⁸)_(4-l), R¹⁹ ₁M″ (OCO—R²⁰—COOR²¹)_(4-l) or     -   (wherein R¹⁷ to R²³ are each independently a hydrocarbon group         of 1 to 20 carbons, M″ is a tin, silicon or germanium atom, and         the letter l is an integer from 0 to 3).

Specific examples of the above terminal modifiers (1) to (7) and methods for their reaction are described in, for example, JP-A 11-35633, JP-A 7-268132 and JP-A 2002-293996.

It is critical for the above-described polybutadiene to be included within the base rubber in an amount of at least 60 wt %, preferably at least 70 wt %, more preferably at least 80 wt %, and most preferably at least 90 wt %, and up to 100 wt %, preferably up to 98 wt %, and more preferably up to 95 wt %. If the amount of the above polybutadiene included is too small, a golf ball endowed with a good rebound will be difficult to obtain.

Rubbers other than the above polybutadiene may also be used and included, insofar as the objects of the invention are attainable. Specific examples include polybutadiene rubbers (BR), styrene-butadiene rubbers (SBR), natural rubbers, polyisoprene rubbers and ethylene-propylene-diene rubbers (EPDM). These may be used individually or as combinations of two or more thereof.

The hot-molded material serving as the solid core is molded from a rubber composition which includes as essential components specific amounts of an unsaturated carboxylic acid and/or a metal salt thereof, an organosulfur compound, an inorganic filler and an organic peroxide per 100 parts by weight of the above-described base rubber.

Specific examples of the unsaturated carboxylic acid include acrylic acid, methacrylic acid, maleic acid and fumaric acid. Acrylic acid and methacrylic acid are especially preferred.

Illustrative examples of the metal salt of the unsaturated carboxylic acid include the zinc and magnesium salts of unsaturated fatty acids such as zinc methacrylate and zinc acrylate. The use of zinc acrylate is especially preferred.

The above unsaturated carboxylic acid and/or metal salt thereof are included in an amount per 100 parts by weight of the base rubber of at least 30 parts by weight, preferably at least 31 parts by weight, and more preferably at least 32 parts by weight, but not more than 45 parts by weight, preferably not more than 43 parts by weight, even more preferably not more than 41 parts by weight, and most preferably not more than 39 parts by weight. Too much unsaturated carboxylic acid component will make the core too hard, giving the golf ball an unpleasant feel on impact. On the other hand, too little will result in a lower rebound.

The organosulfur compound is an essential ingredient for imparting a good rebound. Specifically, it is recommended that a thiophenol, thionaphthol or halogenated thiophenol, or a metal salt thereof, be included. Specific examples include pentachlorothiophenol, pentafluorothiophenol, pentabromothiophenol, p-chlorothiophenol, the zinc salt of pentachlorothiophenol; and diphenylpolysulfides, dibenzylpolysulfides, dibenzoylpolysulfides, dibenzothiazoylpolysulfides and dithiobenzoylpolysulfides having 2 to 4 sulfurs. Diphenyldisulfide and the zinc salt of pentachlorothiophenol are especially preferred.

The amount of the organosulfur compound included per 100 parts by weight of the base rubber is at least 0.1 part by weight, preferably at least 0.2 part by weight, more preferably at least 0.3 part by weight, and most preferably at least 0.4 part by weight, but not more than 5 parts by weight, preferably not more than 4 parts by weight, more preferably not more than 3 parts by weight, and most preferably not more than 2 parts by weight. Too much organosulfur compound makes the core too soft, whereas too little makes an improvement in rebound unlikely.

Illustrative examples of the inert filler include zinc oxide, barium sulfate and calcium carbonate. The amount included per 100 parts by weight of the base rubber is generally at least 5 parts by weight, preferably at least 6 parts by weight, even more preferably at least 7 parts by weight, and most preferably at least 8 parts by weight, but generally not more than 80 parts by weight, preferably not more than 60 parts by weight, more preferably not more than 40 parts by weight, and most preferably not more than 20 parts by weight. Too much or too little inorganic filler will make it impossible to obtain a proper golf ball weight and a suitable rebound.

The organic peroxide may be a commercially available product, suitable examples of which include Percumyl D (produced by NOF Corporation), Perhexa 3M (NOF Corporation), Perhexa 3C(NOF Corporation), and Luperco 231XL (Atochem Co.). If necessary, a combination of two or more different organic peroxides may be used.

The amount of organic peroxide per 100 parts by weight of the base rubber is generally at least 0.1 part by weight, preferably at least 0.2 part by weight, more preferably at least 0.3 part by weight, and most preferably at least 0.4 part by weight, but generally not more than 0.5 part by weight, preferably not more than 0.45 part by weight, and more preferably not more than 0.42 part by weight. Too much or too little organic peroxide may make it impossible to obtain a suitable hardness distribution and, in turn, a good feel on impact, durability and rebound.

In addition, an antioxidant may be included if necessary. Examples of suitable commercial antioxidants include Nocrac NS-6, Nocrac NS-30 (both available from Ouchi Shinko Chemical Industry Co., Ltd.), and Yoshinox 425 (available from Yoshitomi Pharmaceutical Industries, Ltd.). To achieve a good rebound and durability, it is recommended that the amount of antioxidant included per 100 parts by weight of the base rubber be more than 0 part by weight, preferably at least 0.03 part by weight, and more preferably at least 0.05 part by weight, but not more than 0.2 part by weight, preferably not more than 0.1 part by weight, and more preferably not more than 0.08 part by weight.

To ensure good adhesion between the cover layer and the solid core, and also good durability, it is desirable to treat the surface of the solid core with a primer.

Specifically, an adhesive layer may be provided between the solid core and the cover layer in order to enhance the durability of the ball when struck. Examples of adhesives suitable for this purpose include epoxy resin adhesives, vinyl resin adhesives, and rubber adhesives. The use of a urethane resin adhesive or a chlorinated polyolefin adhesive is especially preferred.

The adhesive layer may be formed by dispersion coating. No particular limitation is imposed on the type of emulsion used for dispersion coating. The resin powder used for preparing the emulsion may be a thermoplastic resin powder or a thermoset resin powder. Illustrative examples of suitable resins include vinyl acetate resin, vinyl acetate copolymer resins, ethylene-vinyl acetate (EVA) copolymer resins, acrylate polymer or copolymer resins, epoxy resins, thermoset urethane resins, and thermoplastic urethane resins. Of these, epoxy resins, thermoset urethane resins, thermoplastic urethane resins and acrylate polymer or copolymer resins are preferred. A thermoplastic urethane resin is especially preferred.

The adhesive layer has a thickness of preferably 0.1 to 30 μm, more preferably 0.2 to 25 μm, and especially 0.3 to 20 μm.

The solid core (hot-molded material) can be obtained by vulcanizing and curing the above-described rubber composition by a method similar to that used for known golf ball rubber compositions. Vulcanization can be carried out at, for example, a vulcanization temperature of 100 to 200° C. for a period of 10 to 40 minutes.

The solid core has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kg, of at least 2.0, preferably at least 2.3 mm, more preferably at least 2.7 mm, and most preferably at least 2.8 mm, but not more than 3.5 mm, preferably not more than 3.4 mm, more preferably not more than 3.3 mm, and most preferably not more than 3.2 mm. If the solid core has too small a deformation, the feel of the ball on impact will worsen and the ball will take on too much spin, particularly on long shots with a club such as a driver that significantly deforms the ball. On the other hand, a solid core that is too soft deadens the feel of the ball when played, compromises the rebound of the ball, resulting in a shorter carry, and gives the ball a poor durability to cracking with repeated impact.

In the invention, the solid core has the hardness distribution shown in the following table. TABLE 2 Hardness Distribution in Solid Core Shore D hardness Center 35 to 55 Region located 5 to 10 mm from center 39 to 58 Region located 15 mm from center 48 to 66 Surface 50 to 68 Hardness difference between center and surface  5 to 20

The solid core has a center hardness, expressed in Shore D hardness units, of at least 35, preferably at least 37, more preferably at least 39, and most preferably at least 40, but not more than 55, preferably not more than 52, more preferably not more than 49, and most preferably not more than 45. If the Shore D hardness is too low, the golf ball will have a smaller rebound, whereas if it is too high, the feel of the ball on impact will be too hard, in addition to which the spin rate on shots taken with a driver will increase, which may result in a shorter carry.

The solid core has a hardness in the region thereof located 5 to 10 mm from the center, expressed in Shore D hardness units, of at least 39, preferably at least 41, more preferably at least 43, and most preferably at least 44, but not more than 58, preferably not more than 55, even more preferably not more than 52, and most preferably not more than 49. If the Shore D hardness is too low, the rebound of the ball will decrease, whereas if it is too high, the feel on impact will be too hard, in addition to which the spin rate on shots taken with a driver will increase, which may result in a shorter carry.

The hardness difference between any two places in the region of the solid core located 5 to 10 mm from the center, expressed in Shore D hardness units, is preferably 0 or more, more preferably ±0.2 or more, and even more preferably ±0.5 or more, but preferably not more than ±2, more preferably not more than ±1.7, even more preferably not more than ±1.5, and most preferably not more than ±1.2.

The solid core has a hardness in the region thereof located 15 mm from the center, expressed in Shore D hardness units, of at least 48, preferably at least 50, more preferably at least 51, and most preferably at least 52, but not more than 66, preferably not more than 63, even more preferably not more than 60, and most preferably not more than 57. If the Shore D hardness is too low, the rebound of the ball will decrease, whereas if it is too high, the feel on impact will be too hard, the spin rate on shots taken with a driver will increase, and the ball will have a shorter carry.

The solid core has a hardness at the surface, expressed in Shore D hardness units, of at least 50, preferably at least 52, more preferably at least 53, and most preferably at least 54, but not more than 68, preferably not more than 65, even more preferably not more than 62, and most preferably not more than 59. If the Shore D hardness is too low, the rebound of the ball will decrease, whereas if it is too high, the feel on impact will be too hard, in addition to which the spin rate on shots taken with a driver will increase, which may result in a shorter carry.

The hardness difference between the surface and center of the solid core, expressed in Shore D hardness units, is at least 5, preferably at least 8, more preferably at least 11, and most preferably at least 14, but not more than 20, preferably not more than 19, and most preferably not more than 18. At a hardness difference smaller than foregoing range, the spin rate on shots taken with a driver increases and the carry decreases. Conversely, at a hardness difference larger than the above-indicated range, the rebound and durability decrease.

It is recommended that the solid core have a diameter of at least 37.6 mm, preferably at least 38.2 mm, more preferably at least 38.8 mm, and most preferably at least 39.6 mm, but not more than 43.0 mm, preferably not more than 42.0 mm, even more preferably not more than 41.5 mm, and most preferably not more than 41.0 mm.

It is recommended that the solid core have a specific gravity of generally at least 0.9, preferably at least 1.0, and more preferably at least 1.1, but not more than 1.4, preferably not more than 1.3, and even more preferably not more than 1.2.

In the practice of the invention, the cover layer is formed primarily of a polyurethane material. By forming a cover layer composed primarily of such a polyurethane material, it is possible to achieve an excellent feel, controllability, cut resistance, scuff resistance and durability to cracking on repeated impact without a loss of rebound. The cover may be composed of a single layer or may have a multilayer construction of two or more layers, in which case it is critical for the outermost layer of the cover to be composed primarily of the polyurethane material described here.

In this case, the cover layer is made of a molded resin composition of primarily (A) a thermoplastic polyurethane and (B) a polyisocyanate compound. Such golf balls composed of a thermoplastic polyurethane have an excellent rebound, spin performance and scuff resistance.

The cover layer is composed mainly of a thermoplastic polyurethane, and is formed of a resin composition of primarily (A) a thermoplastic polyurethane and (B) a polyisocyanate compound.

To fully exhibit the advantageous effects of the invention, a necessary and sufficient amount of unreacted isocyanate groups should be present in the cover resin material. Specifically, it is recommended that the total weight of above components A and B combined be at least 60%, and preferably at least 70%, of the overall weight of the cover layer. Components A and B are described in detail below.

The thermoplastic polyurethane serving as component A has a structure which includes soft segments made of a polymeric polyol that is a long-chain polyol (polymeric glycol), and hard segments made of a chain extender and a polyisocyanate compound. Here, the long-chain polyol used as a starting material is not subject to any particular limitation, and may be any that is used in the prior art relating to thermoplastic polyurethanes. Exemplary long-chain polyols include polyester polyols, polyether polyols, polycarbonate polyols, polyester polycarbonate polyols, polyolefin polyols, conjugated diene polymer-based polyols, castor oil-based polyols, silicone-based polyols and vinyl polymer-based polyols. These long-chain polyols may be used singly or as combinations of two or more thereof. Of the long-chain polyols mentioned here, polyether polyols are preferred because they enable the synthesis of thermoplastic polyurethanes having a high rebound resilience and excellent low-temperature properties.

Illustrative examples of the above polyether polyol include poly(ethylene glycol), poly(propylene glycol), poly(tetramethylene glycol) and poly(methyltetramethylene glycol) obtained by the ring-opening polymerization of a cyclic ether. The polyether polyol may be used singly or as a combination of two or more thereof. Of these, poly(tetramethylene glycol) and/or poly(methyltetramethylene glycol) are preferred.

It is preferable for these long-chain polyols to have a number-average molecular weight in a range of 1,500 to 5,000. By using a long-chain polyol having a number-average molecular weight within this range, golf balls made of a thermoplastic polyurethane composition having excellent properties such as resilience and manufacturability can be reliably obtained. The number-average molecular weight of the long-chain polyol is more preferably in a range of 1,700 to 4,000, and even more preferably in a range of 1,900 to 3,000.

As used herein, “number-average molecular weight of the long-chain polyol” refers to the number-average molecular weight computed based on the hydroxyl number measured in accordance with JIS K-1557.

Suitable chain extenders include those used in the prior art relating to thermoplastic polyurethanes. For example, low-molecular-weight compounds which have a molecular weight of 400 or less and have on the molecule two or more active hydrogen atoms capable of reacting with isocyanate groups are preferred. Illustrative, non-limiting, examples of the chain extender include 1,4-butylene glycol, 1,2-ethylene glycol, 1,3-butanediol, 1,6-hexanediol and 2,2-dimethyl-1,3-propanediol. Of these chain extenders, aliphatic diols having 2 to 12 carbons are preferred, and 1,4-butylene glycol is especially preferred.

The polyisocyanate compound is not subject to any particular limitation; preferred use may be made of one that is used in the prior art relating to thermoplastic polyurethanes. Specific examples include one or more selected from the group consisting of 4,4′-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, p-phenylene diisocyanate, xylylene diisocyanate, naphthylene-1,5-diisocyanate, tetramethylxylene diisocyanate, hydrogenated xylylene diisocyanate, dicyclohexylmethane diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, norbornene diisocyanate, trimethylhexamethylene diisocyanate and dimer acid diisocyanate. Depending on the type of isocyanate used, the crosslinking reaction during injection molding may be difficult to control. In the practice of the invention, to provide a balance between stability at the time of production and the properties that are manifested, it is most preferable to use 4,4′-diphenylmethane diisocyanate, which is an aromatic diisocyanate.

It is most preferable for the thermoplastic polyurethane serving as above component A to be a thermoplastic polyurethane synthesized using a polyether polyol as the long-chain polyol, using an aliphatic diol as the chain extender, and using an aromatic diisocyanate as the polyisocyanate compound. It is desirable, though not essential, for the polyether polyol to be a polytetramethylene glycol having a number-average molecular weight of at least 1,900, for the chain extender to be 1,4-butylene glycol, and for the aromatic diisocyanate to be 4,4′-diphenylmethane diisocyanate.

The mixing ratio of activated hydrogen atoms to isocyanate groups in the above polyurethane-forming reaction can be controlled within a desirable range so as to make it possible to obtain a golf ball which is composed of a thermoplastic polyurethane composition and has various improved properties, such as rebound, spin performance, scuff resistance and manufacturability. Specifically, in preparing a thermoplastic polyurethane by reacting the above long-chain polyol, polyisocyanate compound and chain extender, it is desirable to use the respective components in proportions such that the amount of isocyanate groups on the polyisocyanate compound per mole of active hydrogen atoms on the long-chain polyol and the chain extender is from 0.95 to 1.05 moles.

No particular limitation is imposed on the method of preparing the thermoplastic polyurethane used as component A. Production may be carried out by either a prepolymer process or one-shot process in which the long-chain polyol, chain extender and polyisocyanate compound are used and a known urethane-forming reaction is effected. Of these, a process in which melt polymerization is carried out in a substantially solvent-free state is preferred. Production by continuous melt polymerization using a multiple screw extruder is especially preferred.

Illustrative examples of the thermoplastic polyurethane serving as component A include commercial products such as Pandex T8295, Pandex T8290, Pandex T8260, Pandex T8295 and Pandex T8290 (all available from DIC Bayer Polymer, Ltd.).

Next, concerning the polyisocyanate compound used as component B, it is critical that, in at least some of the polyisocyanate compound in the single resin composition, all the isocyanate groups on the molecule remain in an unreacted state. That is, polyisocyanate compound in which all the isocyanate groups on the molecule are in a completely free state must be present within the single resin composition, and such a polyisocyanate compound may be present together with polyisocyanate compound in which some of the isocyanate groups on the molecule are in a free state.

Various types of isocyanates may be employed without particular limitation as this polyisocyanate compound. Illustrative examples include one or more selected from the group consisting of 4,4′-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, p-phenylene diisocyanate, xylylene diisocyanate, naphthylene-1,5-diisocyanate, tetramethylxylene diisocyanate, hydrogenated xylylene diisocyanate, dicyclohexylmethane diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, norbornene diisocyanate, trimethylhexamethylene diisocyanate and dimer acid diisocyanate. Of the above group of isocyanates, the use of 4,4′-diphenylmethane diisocyanate, dicyclohexylmethane diisocyanate and isophorone diisocyanate is preferable in terms of the balance between the influence on processability of such effects as the rise in viscosity that accompanies the reaction with the thermoplastic polyurethane serving as component A and the physical properties of the resulting golf ball cover material.

In the practice of the invention, although not an essential constituent, a thermoplastic elastomer other than the above-described thermoplastic polyurethane may be included as component C together with components A and B. Incorporating this component C in the above resin composition enables the fluidity of the resin composition to be further improved and enables increases to be made in various properties required of golf ball cover materials, such as resilience and scuff resistance.

Component C, which is a thermoplastic elastomer other than the above thermoplastic polyurethane, is exemplified by one or more thermoplastic elastomer selected from the group consisting of polyester elastomers, polyamide elastomers, ionomer resins, styrene block elastomers, hydrogenated styrene-butadiene rubbers, styrene-ethylene/butylene-ethylene block copolymers and modified forms thereof, ethylene-ethylene/butylene-ethylene block copolymers and modified forms thereof, styrene-ethylene/butylene-styrene block copolymers and modified forms thereof, ABS resins, polyacetals, polyethylenes and nylon resins. The use of a polyester elastomer, a polyamide elastomer or a polyacetal is especially preferred for such reasons as enhancing the resilience and scuff resistance while retaining a good manufacturability.

The relative proportions of above components A, B and C are not subject to any particular limitation, although to fully achieve the advantageous effects of the invention, it is preferable for the weight ratio (A):(B):(C) of the respective components to be 100:{2-50}:{0-50}, and more preferably 100:{2-30}:{8-50}.

In the practice of the invention, the resin composition is prepared by mixing component A with component B, and additionally mixing also component C. It is critical to select the mixing conditions such that, of the polyisocyanate compound, at least some polyisocyanate compound is present in which all the isocyanate groups on the molecule remain in an unreacted state. For example, treatment such as the mixture in an inert gas (e.g., nitrogen) or in a vacuum state must be furnished. The resin composition is then injection-molded around a core which has been placed in a mold. To smoothly and easily handle the resin composition, it is preferable for it to be formed into pellets having a length of 1 to 10 mm and a diameter of 0.5 to 5 mm. Isocyanate groups in an unreacted state remain in these resin pellets; while the resin composition is being injection-molded about the core, or due to post-treatment such as annealing, the unreacted isocyanate groups react with component A or component C to form a crosslinked material.

Various additives other than the ingredients making up the above-described thermoplastic polyurethane may be optionally included in the above resin composition. Additives that may be suitably used include pigments, dispersants, antioxidants, light stabilizers, ultraviolet absorbers and parting agents.

The melt mass flow rate (MFR) at 210° C. of the resin composition is not subject to any particular limitation. However, to increase the flow properties and manufacturability, the MFR is preferably at least 5 g/10 min, and more preferably at least 6 g/10 min. Too low a melt mass flow rate reduces the fluidity, which may cause eccentricity during injection molding and may also lower the degree of freedom in the moldable cover thickness. The measured value of the melt mass flow rate is obtained in accordance with JIS-K7210 (1999 edition).

The above method of molding the cover layer is exemplified by feeding the above resin composition to an injection molding machine, and injecting the molten resin composition around the core so as to form a cover layer. The molding temperature varies according to such factors as the type of thermoplastic polyurethane, but is typically in a range of 150 to 250° C.

When injection molding is carried out, it is desirable though not essential to carry out molding in a low-humidity environment such as by purging with a low-temperature gas using an inert gas such as nitrogen or low dew-point dry air or by vacuum treating some or all places on the resin paths from the resin feed area to the mold interior. Illustrative, non-limiting examples of the medium used for transporting the resin include low-moisture gases such as low dew-point dry air or nitrogen gas. By carrying out molding in such a low-humidity environment, reaction by the isocyanate groups is kept from proceeding before the resin has been charged into the mold interior. As a result, polyisocyanate in which the isocyanate groups are present in an unreacted state is included to some degree in the resin molded part, thus making it possible to reduce variable factors such as unwanted rises in viscosity and enabling the essential crosslinking efficiency to be enhanced.

Techniques that could be used to confirm the presence of polyisocyanate compound in an unreacted state within the resin composition prior to injection molding about the core include those which involve extraction with a suitable solvent that selectively dissolves out only the polyisocyanate compound. An example of a simple and convenient method is one in which confirmation is carried out by simultaneous thermogravimetric and differential thermal analysis (TG-DTA) measurement in an inert atmosphere. For example, when the resin composition (cover material) used in the invention is heated in a nitrogen atmosphere at a temperature ramp-up rate of 10° C./min, a gradual drop in the weight of diphenylmethane diisocyanate can be observed from about 150° C. On the other hand, in a resin sample in which the reaction between the thermoplastic polyurethane material and the isocyanate mixture has been carried out to completion, a weight drop from about 150° C. is not observed, but a weight drop from about 230 to 240° C. can be observed.

After the resin composition has been molded as described above, its properties as a golf ball cover can be further improved by carrying annealing so as to induce the crosslinking reaction to proceed further. “Annealing,” as used herein, refers to aging the cover in a fixed environment for a fixed length of time.

At least one of the one or more cover layers on the inventive golf ball is made of the above-described thermoplastic polyurethane composition. The cover layer made of this thermoplastic polyurethane composition has a surface hardness, expressed as the durometer D hardness, of generally 30 to 90, preferably 35 to 85, more preferably 40 to 80, and even more preferably 45 to 75. If the surface hardness of the cover layer is too low, the spin rate when the ball is hit with a driver may increase, shortening the carry of the ball. On the other hand, if the surface hardness of the cover layer is too high, the feel of the ball on impact may worsen and the urethane material may have a poor resilience and durability.

“Durometer D hardness” refers herein to the hardness measured with a type D durometer in accordance with JIS K7215.

The above-described cover layer has a rebound resilience of generally at least 35%, preferably at least 40%, more preferably at least 45%, and even more preferably at least 47%. Because a thermoplastic polyurethane does not inherently have that good a resilience, strict selection of the rebound resilience is preferable. If the rebound resilience of the cover layer is too low, the distance traveled by the golf ball may dramatically decrease. On the other hand, if the rebound resilience of the cover layer is too high, the initial velocity on shots of under 100 yards that require control and on putts may be too high and the feel of the ball when played may not agree with the golfer. “Rebound resilience” refers herein to the rebound resilience obtained in accordance with JIS K7311.

The cover has a surface hardness, expressed in Shore D hardness units, of at least 50, preferably at least 53, more preferably at least 56, even more preferably at least 58, and most preferably at least 60, but not more than 70, preferably not more than 68, more preferably not more than 66, and most preferably not more than 65. If the cover is too soft, the ball will have a greater spin receptivity and an inadequate rebound, shortening the distance of travel, in addition to which the cover will have a poor scuff resistance. On the other hand, if the cover is too hard, the durability to cracking with repeated impact will decrease and the feel of the ball during the short game and when hit with a putter will worsen. The Shore D hardness of the cover is the value measured with a type D durometer according to ASTM D2240.

The cover material has a flexural rigidity of at least 50 MPa, preferably at least 60 MPa, and more preferably at least 70 MPa, but not more than 300 MPa, preferably not more than 280 MPa, even more preferably not more than 260 MPa, and most preferably not more than 240 MPa. By giving the cover a flexural rigidity that is low relative to its hardness, there can be obtained a cover stock suitable for good spin characteristics and controllability on approach shots.

To achieve the desired spin properties on shots taken with a driver, the core must have a surface hardness that is lower than the surface hardness of the cover. Specifically, the surface hardness difference between the core and the cover, expressed in Shore D hardness units, is set to at least 1, preferably at least 2, and more preferably at least 5, but not more than 15, preferably not more than 13, and more preferably not more than 11.

The cover has a thickness of at least 0.5 mm, preferably at least 0.8 mm, more preferably at least 1.1 mm, even more preferably at least 1.4 mm, and most preferably at least 1.7 mm, but not more than 2.5 mm, preferably not more than 2.3 mm, more preferably not more than 2.1 mm, and most preferably not more than 2.0 mm. If the cover is too thin, the durability to cracking with repeated impact worsens and the resin has difficulty spreading properly through the top portion of the mold during injection molding, which may result in a poor sphericity. On the other hand, if the cover is too thick, the ball takes on increased spin when hit with a number one wood (W#1), shortening the carry, in addition to which the ball has too hard a feel on impact.

The cover in the inventive golf ball may be composed of a single layer or may be composed of two or more layers. If the cover is composed of two or more layers, it is essential for the hardness of the outside layer and the overall thickness of the cover to fall within the above-specified ranges. The cover may be formed using a suitable known method, such as by injection-molding the cover directly over the core, or by covering the core with two half-cups that have been molded beforehand as hemispherical shells, then molding under applied heat and pressure.

Numerous dimples are formed on the surface of the golf ball (surface of the cover layer). The number of dimples is generally at least 250, preferably at least 270, more preferably at least 290, and most preferably at least 310, but generally not more than 450, preferably not more than 440, more preferably not more than 420, and most preferably not more than 400. In the invention, within this range, the ball undergoes lift and the carry of the ball on shots taken with a driver can be increased. To achieve a suitable trajectory, it is desirable for the dimples to be given a shape that is circular as seen from above. The average dimple diameter is preferably at least 3.5 mm, more preferably at least 3.6 mm, and even more preferably at least 3.8 mm, but preferably not more than 5.0 mm, more preferably not more than 4.7 mm, even more preferably not more than 4.5 mm, and most preferably not more than 4.3 mm. The average dimple depth is preferably at least 0.125 mm, more preferably at least 0.130 mm, even more preferably at least 0.133 mm, and most preferably at least 0.135 mm, but preferably not more than 0.170 mm, more preferably not more than 0.160 mm, even more preferably not more than 0.150 mm, and most preferably not more than 0.148 mm. Moreover, the dimples are composed of preferably at least 4 types, more preferably at least 5 types, and even more preferably at least 6 types, of mutually differing diameter and/or depth. While there is no particular upper limit on the number of dimple types, it is recommended that there be not more than 20 types, preferably not more than 15 types, more preferably not more than 12 types, and most preferably not more than 9 types.

As used herein, “average depth” refers to the mean value for the depths of all the dimples. The diameter of a dimple is measured as the distance across the dimple between positions where the dimple region meets land areas (non-dimple regions), that is, between the highest points of the dimple region. The golf ball is usually painted, in which case the dimple diameter refers to the diameter when the surface of the ball is covered with paint. The depth of a dimple is measured by connecting together the positions where the dimple meets the surrounding land areas so as to define an imaginary plane, and determining the vertical distance from a center position on the plane to the bottom (deepest position) of the dimple.

If necessary, the surface of the solid golf ball can be marked, painted and surface treated.

The solid golf ball of the invention has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kgf, of at least 2.0 mm, preferably at least 2.2 mm, more preferably at least 2.4 mm, and even more preferably at least 2.5 mm, but not more than 2.9 mm, and preferably not more than 2.8 mm.

The solid golf ball of the invention can be manufactured in accordance with the Rules of Golf for use in competitive play, in which case the ball may be formed to a diameter of not less than 42.67 mm and a weight of not more than 45.93 g. The upper limit for the diameter is generally not more than 44.0 mm, preferably not more than 43.8 mm, more preferably not more than 43.5 mm, and most preferably not more than 43.0 mm. The lower limit for the weight is generally not less than 44.5 g, preferably not less than 45.0 g, more preferably not less than 45.1 g, and even more preferably not less than 45.2 g.

In the solid golf ball of the invention, by optimizing the hardness distribution of the solid core, selection of the cover material, the hardnesses of the solid core and the cover, and the amount of deflection by the ball as a whole, the rebound is enhanced and the spin rate of the ball on full shots with a driver is reduced, increasing the distance traveled by the ball. Moreover, compared with an ordinary ionomer cover, the cover has a low flexural rigidity that is relatively low for its hardness, resulting in an excellent spin performance on approach shots and a very high stability. In addition, the inventive golf ball also has an excellent scuff resistance and excellent durability to cracking on repeated impact, making it overall a highly advantageous ball for use in competitive play.

EXAMPLES

The following Examples of the invention and Comparative Examples are provided by way of illustration and not by way of limitation.

Examples 1 to 9, Comparative Examples 1 to 8

In each example, a solid core was manufactured by preparing a core composition having one of formulations No. 1 to 11 shown in Table 3, then molding and vulcanizing the composition under the vulcanization conditions in Table 3. Next, a single-layer cover was formed by injection molding about the core one of the formulations a, b, c & d shown in Table 4, thereby encasing the solid core within a cover. In addition, a plurality of dimple types were used in combination, giving a two-piece solid golf ball having 330 dimples (configuration I), 432 dimples (configuration II) or 500 dimples (configuration III).

In Examples and Comparative Examples using the cover formulations a or b shown in Table 4, the starting materials shown in Table 4 (units: parts by weight) were worked in a twin-screw extruder and under a nitrogen gas atmosphere, thereby giving cover resin compositions. These resin compositions were in the form of pellets having a length of 3 mm and a diameter of 1 to 2 mm.

And, the solid core was placed within an injection-molding mold and the cover material was injection-molded around the core, thereby giving two-piece golf balls having a cover. Samples for measuring the physical properties of the cover were prepared by injection-molding a predetermined thick sheet, annealing the molded sheet for 8 hours at 100° C., then holding the annealed sheet at room temperature for one week.

In Comparative Example 7 using the cover formulation c shown in Table 4, the solid core was placed within an injection-molding mold and a dry blend of thermoplastic polyurethane pellets with isocyanate mixture pellets was injection-molded around the core, thereby giving two-piece golf balls having a cover. Subsequent treatment was carried out in the same way as described above for the examples of the invention. In Comparative Example 8 using the cover formulation d shown in Table 4, only pellets composed entirely of thermoplastic polyurethane were injection-molded, and annealing was not carried out. TABLE 3 No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 Core BR11 100 formulations BR730 100 100 100 100 100 100 100 100 100 100 Perhexa C-40 0.3 0.3 0.3 0.3 0.3 0.3 0.3 1 0.3 0.3 0.6 (true amount of addition) 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.4 0.12 0.12 0.24 Percumyl D 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.6 Zinc oxide 10.6 11.3 9.1 9.4 10.4 5.2 14.1 10.6 21.3 8.7 11.2 Antioxidant 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Zinc stearate 5 5 5 5 5 0 5 5 5 5 5 Zinc acrylate 37 32 38 37 34 46 28 34 30 39 32 Zinc salt of 0.4 1 0.4 0.6 1 0 1 1 1 0.2 1 pentachlorothiophenol Vulcanization Primary Temp. 160 160 160 160 160 160 160 135 160 160 160 conditions vulcanization (° C.) Time 13 13 13 13 13 13 13 40 13 13 13 (min) Secondary Temp. 170 vulcanization (° C.) Time 5 (min) Numbers in the “Core formulations” portion of the table indicate parts by weight.

Trade names for most of the materials appearing in the table are as follows.

-   -   BR11: A polybutadiene rubber produced by JSR Corporation using a         nickel catalyst; cis-1,4 bond content, 96%; 1,2-vinyl bond         content, 2.0%; Mooney viscosity, 43; Mw/Mn=4.1.     -   BR730: A polybutadiene rubber produced by JSR Corporation using         a neodymium catalyst; cis-1,4 bond content, 96%; 1,2-vinyl bond         content, 1.3%; Mooney viscosity, 55; Mw/Mn=3.     -   Perhexa C-40: 1,1-Bis(t-butylperoxy)cyclohexane, 40% dilution;         produced by NOF Corporation. Because Perhexa C-40 is a 40%         dilution, the true amount of addition is also indicated in the         above table.     -   Percumyl D: Dicumyl peroxide, produced by NOF Corporation.     -   Zinc oxide: Produced by Sakai Chemical Industry Co., Ltd.     -   Antioxidant: 2,2′-Methylenebis(4-methyl-6-t-butylphenol),         produced as Nocrac NS-6 by Ouchi Shinko Chemical Industry Co.     -   Zinc acrylate: Produced by Nihon Jyoryu Kogyo Co., Ltd.

Zinc stearate: Produced by NOF Corporation TABLE 4 a b c d Pandex T8260 50 50 50 Pandex T8295 50 100 50 50 Isocyanate Compound 9 9 Isocyanate Mixture 20 Thermoplastic Elastomer 15 15 Titanium oxide 3.5 3.5 3.5 3.5 Ultramarine blue 0.4 0.4 0.4 0.4 Polyethylene wax 1.5 1.5 1.5 1.5 Montan wax 0.8 0.8 0.8 0.8 MFR (at 210° C.) 7.5 7.8 2.2 1.8 Numbers in the table indicate parts by weight.

Trade names for most of the materials appearing in the table are as follows.

“Pandex T8260”

A MDI-PTMG-type thermoplastic polyurethane material having a Durometer D resin hardness of 56 and a rebound resilience of 45%, produced by DIC Bayer Polymer, Ltd.

“Pandex T8295”

A MDI-PTMG-type thermoplastic polyurethane material having a resin hardness of JIS-A97 and a rebound resilience of 44%, produced by DIC Bayer Polymer, Ltd.

Isocyanate Compound

4,4′-Diphenylmethane diisocyanate

Isocyanate Mixture

Crossnate EM-30 (an isocyanate masterbatch produced by Dainichiseika Color & Chemicals Mfg. Co., Ltd.; 4,4′-diphenylmethane diisocyanate content, 30%; the masterbatch base resin was a polyester elastomer).

Thermoplastic Elastomer

A thermoplastic polyetherester elastomer (Hytrel 4001, produced by DuPont-Toray Co., Ltd.) was used.

Polyethylene Wax

Sanwax 161P, produced by Sanyo Chemical Industries, Ltd.

Montan Wax

Licowax E, produced by (Clariant Japan) K. K.

Melt Mass Flow Rate (MFR)

The melt flow rate (or melt index) of the material was measured in accordance with JIS-K7210 (test temperature, 210° C.; test load, 21 N (2.16 kgf)).

The golf balls obtained in above Examples 1 to 9 and Comparative Examples 1 to 8 were each evaluated for ball deflection, ball properties, flight performance, spin rate on approach shots, scuff resistance, feel when hit, and ball manufacturability. The results are shown in Tables 5 and 6.

Hardness Distribution of Solid Core (Shore D Hardness)

The balls were temperature conditioned at 23° C., then both of the following hardnesses were measured in terms of the Shore D hardness (using a type D durometer in accordance with ASTM-2240).

Each surface hardness shown in the table was obtained by measuring the hardness at any two randomly chosen points on the surface of each of five cores, and determining the average of the measured values.

Each center hardness shown in the table was obtained by cutting the solid core into two halves with a fine cutter, measuring the hardness at the center of the sectioned plane on the two hemispheres for each of five cores, and determining the average of the measured values.

Each cross-sectional hardness shown in the table was obtained by cutting the solid core into two halves, measuring the hardness at the appropriate region of the sectioned plane on the two hemispheres for each of five cores, and determining the average of the measured values.

Surface Hardness of Cover

The balls were temperature conditioned at 23° C., following which the hardness at two randomly chosen points in undimpled land areas on the surface of each of five balls were measured. Measurements were conducted with a type D durometer in accordance with ASTM-2240.

Rebound Resilience of Cover Material

The rebound resilience was measured in accordance with JIS-K7311.

Deflection of Solid Core and Finished Ball

Using an Instron model 4204 test system manufactured by Instron Corporation, solid cores and finished balls were each compressed at a rate of 10 mm/min, and the difference between deformation at 10 kg and deformation at 130 kg was measured.

Initial Velocity

The initial velocity was measured using an initial velocity measuring apparatus of the same type as the USGA drum rotation-type initial velocity instrument approved by the R&A. The ball was temperature conditioned at 23±1° C. for at least 3 hours, then tested in a chamber at a room temperature of 23±2° C. The ball was hit using a 250-pound (113.4 kg) head (striking mass) at an impact velocity of 143.8 ft/s (43.83 m/s). One dozen balls were each hit four times. The time taken to traverse a distance of 6.28 ft (1.91 m) was measured and used to compute the initial velocity of the ball. This cycle was carried out over a period of about 15 minutes.

Distance

The total distance traveled by the ball when hit at a head speed (HS) of 45 m/s with a driver (Tour Stage X-DRIVE TYPE 350 PROSPEC, manufactured by Bridgestone Sports Co., Ltd.; loft angle, 8°) mounted on a swing robot (Miyamae Co., Ltd.) was measured. The spin rate was measured from high-speed camera images of the ball taken immediately after impact.

Spin Rate on Approach Shots

The spin rate of a ball hit at a head speed of 20 m/s with a sand wedge (abbreviated below as “SW”; Tour Stage X-wedge, manufactured by Bridgestone Sports Co., Ltd.; loft angle, 58°) was measured. The spin rate was measured by the same method as that used above when measuring distance.

Feel

The feel of each ball when teed up and hit with a driver and when hit with a putter was evaluated by ten amateur golfers, and was rated as indicated below based on the number of golfers who responded that the ball had a “soft” feel. An X-DRIVE TYPE 350 PROSPEC having a loft angle of 10° was used as the driver, and a Tour Stage ViQ Model-III was used as the putter. Both clubs are manufactured by Bridgestone Sports Co., Ltd.

Poor: 1 to 3 golfers rated the ball as “soft.”

Ordinary: 4 to 6 golfers rated the ball as “soft.”

Good: 7 to 10 golfers rated the ball as “soft.”

Scuff Resistance

Each ball was temperature conditioned at 23° C., and hit at a head speed of 33 m/s with a square grooved pitching wedge mounted on a swing robot. The condition of the ball after being hit was rated visually by three judges according to the following criteria. Results shown in the table are the average point values obtained for each ball.

10 points: No visible defects.

8 points: Substantially no defects.

5 points: Some defects noted, but ball can be re-used.

3 points: Condition is borderline, but ball can be re-used.

1 point: Unfit for reuse. TABLE 5 Example 1 2 3 4 5 Solid Type No. 1 No. 2 No. 4 No. 5 No. 2 core Diameter (mm) 41.0 38.0 38.9 38.9 38.9 Deflection (mm) 2.8 3.4 2.8 3.2 3.4 Hardness Center hardness 41 39 46 41 39 distribution Region 5 mm from center 47 44 52 47 44 (Shore D) Region 10 mm from center 48 46 53 48 46 Region 15 mm from center 54 52 58 54 52 Surface 57 55 63 57 55 Hardness difference 16 16 17 16 16 between center and surface Cover Type a a a a a (single Surface hardness (Shore D) 64 64 64 64 64 layer) Rebound resilience (%) 55 55 55 55 55 Hardness difference between cover 7 9 1 7 9 surface and core surface (Shore D) Finished Deflection (mm) 2.6 2.8 2.4 2.7 2.9 ball Diameter (mm) 42.7 42.7 42.7 42.7 42.7 Weight (g) 45.4 45.5 45.4 45.4 45.4 Specific gravity 1.16 1.16 1.16 1.16 1.16 Thickness (mm) 0.8 2.3 1.9 1.9 1.9 Dimples Number of dimples 330 432 330 330 330 Average dimple depth (mm) 0.146 0.142 0.146 0.146 0.146 Average dimple diameter (mm) 4.2 3.6 4.2 4.2 4.2 Number of dimple types 6 5 6 6 6 Distance Spin rate (rpm) 2720 2640 2810 2680 2590 Total distance (m) 236.5 230.5 237.0 235.5 233.5 Spin on approach shots (rpm) 6360 6070 6410 6170 5950 Initial velocity (m/s) 77.6 77.0 77.6 77.5 77.3 Scuff resistance 7.0 7.5 6.5 7.5 8.0 Feel on impact Driver ◯ ◯ ◯ ◯ ◯ Putter ◯ ◯ ◯ ◯ ◯ Example 6 7 8 9 Solid Type No. 5 No. 5 No. 5 No. 2 core Diameter (mm) 38.9 38.9 38.9 38.9 Deflection (mm) 3.2 3.2 3.2 3.4 Hardness Center hardness 41 41 41 39 distribution Region 5 mm from center 47 47 47 44 (Shore D) Region 10 mm from center 48 50 48 46 Region 15 mm from center 54 53 54 52 Surface 57 57 57 55 Hardness difference 16 16 16 16 between center and surface Cover Type b a a a (single Surface hardness (Shore D) 63 64 64 64 layer) Rebound resilience (%) 56 55 55 55 Hardness difference between cover 6 7 7 9 surface and core surface (Shore D) Finished Deflection (mm) 2.8 2.7 2.7 2.9 ball Diameter (mm) 42.7 42.7 42.7 42.7 Weight (g) 45.4 45.4 45.4 45.4 Specific gravity 1.16 1.16 1.16 1.16 Thickness (mm) 1.9 1.9 1.9 1.9 Dimples Number of dimples 330 330 432 432 Average dimple depth (mm) 0.146 0.146 0.142 0.142 Average dimple diameter (mm) 4.2 4.2 3.6 3.6 Number of dimple types 6 6 5 5 Distance Spin rate (rpm) 2750 2650 2690 2580 Total distance (m) 235.0 236.0 233.5 231.5 Spin on approach shots (rpm) 6650 6140 6160 5960 Initial velocity (m/s) 77.5 77.3 77.5 77.3 Scuff resistance 8.0 7.5 7.5 8.0 Feel on impact Driver ◯ ◯ ◯ ◯ Putter ◯ ◯ ◯ ◯

TABLE 6 Comparative Example 1 2 3 4 5 6 7 8 Solid Type No. 6 No. 7 No. 8 No. 5 No. 10 No. 11 No. 5 No. 5 core Diameter (mm) 38.9 40.3 38.9 37.5 38.9 38.9 38.9 38.9 Deflection (mm) 1.9 3.8 2.8 3.2 2.4 3.2 3.2 3.2 Hardness Center hardness 56 35 55 41 50 41 41 41 distribution Region 5 mm from center 62 40 56 47 56 47 47 47 (Shore D) Region 10 mm from center 63 42 57 48 58 48 48 48 Region 15 mm from center 68 45 57 54 63 54 54 54 Surface 74 49 58 57 68 57 57 57 Hardness difference 18 14 3 16 18 16 16 16 between center and surface Cover Type a a a a a a c d (single Surface hardness (Shore D) 64 64 64 64 64 64 65 63 layer) Rebound resilience (%) 55 55 55 55 55 55 45 44 Hardness difference between cover −10 15 6 7 −4 7 8 6 surface and core surface (Shore D) Finished Deflection (mm) 1.7 3.6 2.4 2.3 2.0 2.7 2.7 2.7 ball Diameter (mm) 42.7 42.7 42.7 42.7 42.7 42.7 42.7 42.7 Weight (g) 45.4 45.5 45.4 45.6 45.4 45.4 45.4 45.4 Specific gravity 1.16 1.16 1.16 1.16 1.16 1.16 1.16 1.16 Thickness (mm) 1.9 1.2 1.9 2.6 1.9 1.9 1.9 1.9 Dimples Number of dimples 330 330 330 330 500 330 432 432 Average dimple depth (mm) 0.146 0.146 0.146 0.146 0.153 0.146 0.142 0.142 Average dimple diameter (mm) 4.2 4.2 4.2 4.2 3.1 4.2 3.6 3.6 Number of dimple types 6 6 6 6 3 6 5 5 Distance Spin rate (rpm) 3160 2450 3110 2600 3060 2680 2700 2730 Total distance (m) 230.0 229.5 228.5 229.5 228.0 230.0 233.0 231.5 Spin on approach shots (rpm) 6770 5780 6500 5810 6110 6160 6170 6210 Initial velocity (m/s) 77.6 76.9 77.3 76.8 77.4 76.9 77.5 77.4 Scuff resistance 4.0 9.0 7.5 7.0 5.5 7.5 5.5 3.0 Feel on impact Driver X ◯ Δ X Δ ◯ ◯ ◯ Putter Δ ◯ ◯ ◯ Δ ◯ ◯ ◯ Ball Manufacturability

In Comparative Examples 8 & 9, the molding conditions during mass production were unstable and high frequency of problems such as resin scorching. In all Examples and the other Examples, the molding conditions during mass production were stable and the problems such as scorching of resin were infrequent.

The results in Tables 5 and 6 show that, in Comparative Example 1, the finished ball had a hardness that was too high, resulting in a hard feel when hit, and also resulting in an excessive spin rate which shortened the distance traveled by the ball. In Comparative Example 2, the finished ball had a hardness that was too low, reducing the rebound and shortening the carry, and also lowering the performance of the ball on approach shots. In Comparative Example 3, the core lacked much of a hardness distribution, resulting in a high spin rate, a shorter carry and a lower rebound. In Comparative Example 4, the cover was too thick, as a result of which a good rebound was not obtained, shortening the distance traveled by the ball. In Comparative Example 5, the cover was softer than the surface of the core, resulting in an excessive spin rate and a shorter distance. In Comparative Example 6, the use of a polybutadiene rubber synthesized with a nickel catalyst as the core material resulted in a lower rebound and a shorter distance.

In Comparative Example 7, a dry blend of thermoplastic polyurethane pellets with isocyanate mixture pellets was injection-molded as a cover material, as a result of which the scuff resistance was poor. In Comparative Example 8, only pellets composed entirely of thermoplastic polyurethane were injection-molded as a cover material, as a result of which the scuff resistance was very poor. 

1. A solid golf ball comprising a solid core, a cover layer that encloses the core, and a plurality of dimples formed on an outside surface of an outermost layer of the cover, the solid golf ball being characterized in that the solid core is formed of a rubber composition composed of 100 parts by weight of a base rubber that includes 60 to 100 parts by weight of a polybutadiene rubber having a cis-1,4 bond content of at least 60% and synthesized using a rare-earth catalyst, 0.1 to 5 parts by weight of an organosulfur compound, and an unsaturated carboxylic acid or a metal salt thereof, an organic peroxide and an inorganic filler; the solid core has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kg, of 2.0 to 3.5 mm, and has the hardness distribution shown in the table below; the cover layer is formed by injection-molding a single resin composition of primarily (A) a thermoplastic polyurethane and (B) a polyisocyanate compound, and at least some polyisocyanate compound in which all the isocyanate groups on the molecule remain in an unreacted state is present in the resin composition, and has a thickness of 0.5 to 2.5 mm, a Shore D hardness at the surface of 50 to 70 and, the surface hardness of the core is from 1 to 15 Shore D hardness units lower than the surface hardness of the cover; and the golf ball has a deformation, when subjected to loading from an initial load of 10 kgf to a final load of 130 kgf, of 2.0 to 2.9 mm. Hardness Distribution in Solid Core Shore D hardness Center 35 to 55 Region located 5 to 10 mm from center 39 to 58 Region located 15 mm from center 48 to 66 Surface 50 to 68 Hardness difference between center and surface  5 to 20


2. The solid golf ball of claim 1, wherein the solid core has a diameter of 37.6 to 43.0 mm and the golf ball has a diameter of 42.67 to 44.0 mm.
 3. The solid golf ball of claim 1, wherein the solid core contains, per 100 parts by weight of the base rubber: 30 to 45 parts by weight of the unsaturated carboxylic acid or a metal salt thereof, 0.1 to 0.5 part by weight of the organic peroxide, 5 to 80 parts by weight of the inorganic filler, and 0 to 0.2 part by weight of an antioxidant.
 4. The solid golf ball of claim 1 which has a hardness difference between any two places in the region of the solid core located 5 to 10 mm from the core center of not more than ±2 Shore D hardness units.
 5. The solid golf ball of claim 1, wherein the dimples total in number from 250 to 450, have an average depth of 0.125 to 0.170 mm and an average diameter of 3.5 to 5.0 mm for all dimples, and are configured from at least four dimple types.
 6. The solid golf ball of claim 1, wherein the resin composition additionally includes (C) a thermoplastic elastomer other than thermoplastic polyurethane.
 7. The solid golf ball of claim 6, wherein some of the isocyanate groups in component B form bonds with active hydrogens in component A and/or component C, and the other isocyanate groups remain in an unreacted state within the resin composition.
 8. The solid golf ball of claim 6, wherein the weight ratio (A):(B):(C) of the respective components is 100:{2-50}:{0-50}.
 9. The solid golf ball of claim 6, wherein the weight ratio (A):(B):(C) of the respective components is 100:{2-30}:{8-50}.
 10. The solid golf ball of claim 1, wherein the total weight of components A and B combined is at most 90 wt % of the overall weight of the cover layer.
 11. The solid golf ball of claim 1, wherein the resin composition has a melt mass flow rate (MFR) at 210° C. of at least 5 g/10 min.
 12. The solid golf ball of claim 1, wherein component B is one or more polyisocyanate compound selected from the group consisting of 4,4′-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, p-phenylene diisocyanate, xylylene diisocyanate, naphthylene-1,5-diisocyanate, tetramethylxylene diisocyanate, hydrogenated xylylene diisocyanate, dicyclohexylmethane diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, norbornene diisocyanate, trimethylhexamethylene diisocyanate and dimer acid diisocyanate.
 13. The solid golf ball of claim 1, wherein component B is one or more polyisocyanate compound selected from the group consisting of 4,4′-diphenylmethane diisocyanate, dicyclohexylmethane diisocyanate and isophorone diisocyanate.
 14. The solid golf ball of claim 1, wherein component C is one or more thermoplastic elastomer selected from the group consisting of polyester elastomers, polyamide elastomers, ionomer resins, styrene block elastomers, hydrogenated styrene-butadiene rubbers, styrene-ethylene/butylene-ethylene block copolymers and modified forms thereof, ethylene-ethylene/butylene-ethylene block copolymers and modified forms thereof, styrene-ethylene/butylene-styrene block copolymers and modified forms thereof, ABS resins, polyacetals, polyethylenes and nylon resins.
 15. The solid golf ball of claim 1, wherein component C is one or more selected from the group consisting of polyester elastomers, polyamide elastomers and polyacetals. 